US20180119838A1 - Modular electro-mechanical rotary valve - Google Patents
Modular electro-mechanical rotary valve Download PDFInfo
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- US20180119838A1 US20180119838A1 US15/341,622 US201615341622A US2018119838A1 US 20180119838 A1 US20180119838 A1 US 20180119838A1 US 201615341622 A US201615341622 A US 201615341622A US 2018119838 A1 US2018119838 A1 US 2018119838A1
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- rotary valve
- inlet
- valve body
- electro
- outlet
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K27/00—Construction of housing; Use of materials therefor
- F16K27/06—Construction of housing; Use of materials therefor of taps or cocks
- F16K27/067—Construction of housing; Use of materials therefor of taps or cocks with spherical plugs
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01P—COOLING OF MACHINES OR ENGINES IN GENERAL; COOLING OF INTERNAL-COMBUSTION ENGINES
- F01P7/00—Controlling of coolant flow
- F01P7/02—Controlling of coolant flow the coolant being cooling-air
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01P—COOLING OF MACHINES OR ENGINES IN GENERAL; COOLING OF INTERNAL-COMBUSTION ENGINES
- F01P7/00—Controlling of coolant flow
- F01P7/14—Controlling of coolant flow the coolant being liquid
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01P—COOLING OF MACHINES OR ENGINES IN GENERAL; COOLING OF INTERNAL-COMBUSTION ENGINES
- F01P7/00—Controlling of coolant flow
- F01P7/14—Controlling of coolant flow the coolant being liquid
- F01P7/16—Controlling of coolant flow the coolant being liquid by thermostatic control
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K11/00—Multiple-way valves, e.g. mixing valves; Pipe fittings incorporating such valves
- F16K11/02—Multiple-way valves, e.g. mixing valves; Pipe fittings incorporating such valves with all movable sealing faces moving as one unit
- F16K11/08—Multiple-way valves, e.g. mixing valves; Pipe fittings incorporating such valves with all movable sealing faces moving as one unit comprising only taps or cocks
- F16K11/087—Multiple-way valves, e.g. mixing valves; Pipe fittings incorporating such valves with all movable sealing faces moving as one unit comprising only taps or cocks with spherical plug
- F16K11/0873—Multiple-way valves, e.g. mixing valves; Pipe fittings incorporating such valves with all movable sealing faces moving as one unit comprising only taps or cocks with spherical plug the plug being only rotatable around one spindle
- F16K11/0876—Multiple-way valves, e.g. mixing valves; Pipe fittings incorporating such valves with all movable sealing faces moving as one unit comprising only taps or cocks with spherical plug the plug being only rotatable around one spindle one connecting conduit having the same axis as the spindle
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K27/00—Construction of housing; Use of materials therefor
- F16K27/003—Housing formed from a plurality of the same valve elements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K31/00—Actuating devices; Operating means; Releasing devices
- F16K31/02—Actuating devices; Operating means; Releasing devices electric; magnetic
- F16K31/04—Actuating devices; Operating means; Releasing devices electric; magnetic using a motor
- F16K31/041—Actuating devices; Operating means; Releasing devices electric; magnetic using a motor for rotating valves
- F16K31/043—Actuating devices; Operating means; Releasing devices electric; magnetic using a motor for rotating valves characterised by mechanical means between the motor and the valve, e.g. lost motion means reducing backlash, clutches, brakes or return means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K31/00—Actuating devices; Operating means; Releasing devices
- F16K31/44—Mechanical actuating means
- F16K31/53—Mechanical actuating means with toothed gearing
- F16K31/535—Mechanical actuating means with toothed gearing for rotating valves
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01P—COOLING OF MACHINES OR ENGINES IN GENERAL; COOLING OF INTERNAL-COMBUSTION ENGINES
- F01P7/00—Controlling of coolant flow
- F01P7/14—Controlling of coolant flow the coolant being liquid
- F01P2007/146—Controlling of coolant flow the coolant being liquid using valves
Definitions
- Example aspects described herein relate to electro-mechanical rotary valves for use within fluid cooling systems of vehicular powertrains.
- Coolant valves are well known and can be arranged to provide coolant flow control for temperature management of various powertrain components including internal combustion engines, transmissions and various components of hybrid electric and fuel cell vehicles.
- a portion of coolant valves are electro-mechanical in design, incorporating an actuator assembly that interfaces with a mechanical rotary valve body to provide a controlled flow of coolant to a selected powertrain component or system.
- An electric motor controlled by the engine control unit, is often employed within the actuator assembly of the electro-mechanical rotary valve (EMRV) to achieve any desired angular position of the rotary valve body.
- EMRV electro-mechanical rotary valve
- a transmission or gear train can be utilized between the electric motor and rotary valve body.
- An injection molded plastic outer housing is typically used for an EMRV that is often mounted directly on either a cylinder head or cylinder block of the IC engine.
- plastic provides a light-weight solution to fulfill complex outer housing design specifications that are required for mounting and sealing the EMRV to the engine, providing connections for hoses, and guiding and sealing the internal rotary valve.
- the outer housing must be able to withstand the rigors of a vibrating IC engine, which include large temperature fluctuations and exposure to dust, water, and salt. Additionally, all of the fasteners for either mounting or sealing of the hoses must be accessible within a crowded IC engine compartment.
- the outer housing is often one of the higher priced components of the EMRV and also contributes to many failure modes that could occur. Amongst all of the components of the EMRV, the outer housing typically requires the most time and effort to achieve a production-worthy design. A new design for an EMRV is needed that addresses these shortcomings while maintaining critical functions for current and future applications.
- a modular electro-mechanical rotary valve (EMRV) is provided that eliminates a traditional outer housing and instead utilizes a mating cavity integrated within a powertrain component or any other receiving structure.
- “Modular” describes the scalability, flexibility, and simplicity of the modular EMRV that can easily be installed and removed as a unit within the mating cavity, which reduces packaging space and component cost while increasing robustness and serviceability.
- the modular EMRV includes a valve enclosure, at least one rotary valve body, and an actuator assembly.
- the valve enclosure includes a central axis, at least one inlet, at least one outlet, a hollow center, and at least one exterior seal interface.
- the at least one exterior seal interface sealingly engages with at least one interior seal interface arranged within the mating cavity. At least one seal may be present between the at least one exterior seal interface and the at least one interior seal interface.
- the at least one rotary valve body includes at least one fluid pathway, a central axis, and an actuator interface.
- the actuator assembly can be located at a first end and the at least one outlet can be located at a second end of the valve enclosure.
- the at least one inlet can be radially arranged on the valve enclosure.
- the at least one rotary valve body is disposed within the hollow center of the valve enclosure. To facilitate a reduced packaging space, the central axis of the valve enclosure can be offset from a central axis of the at least one rotary valve body.
- the actuator assembly includes an actuator that rotationally actuates the at least one rotary valve body to achieve any desired angular or rotational position. Continuously variable angular positions of the at least one rotary valve body are possible to manage the fluid flows and subsequent temperatures of a fluid-cooled system.
- a first rotational position of the rotary valve body can provide full fluid flow from the inlet to the outlet; a second rotational position can prevent fluid flow from the inlet to the outlet; and, an intermediate position can throttle the flow from the inlet to the outlet.
- a gear train can be arranged between the actuator and rotary valve body.
- a drive shaft can also be arranged between the gear train and rotary valve body, with a first end of the drive shaft engaged with the gear train and a second end engaged with the rotary valve body.
- the mating cavity for the modular EMRV can be configured within but not limited to a powertrain component such as an internal combustion engine (for example, a cylinder head, engine block or front cover), transmission, or differential.
- the mating cavity can extend inwardly or protrude outwardly from an outer wall of the powertrain component or any other receiving structure.
- the mating cavity serves as a fluid terminal for intersecting fluid flow paths that interface with the valve enclosure of the modular EMRV; the flow of fluid within each of these fluid flow paths is managed by an angular or rotational position of the at least one rotary valve body disposed within the valve enclosure.
- Both the valve enclosure and mating cavity can be cylindrical in shape.
- FIG. 1 is a perspective view of an example embodiment of a modular electro-mechanical rotary valve (EMRV).
- EMRV electro-mechanical rotary valve
- FIG. 2 is another perspective view of the modular EMRV of FIG. 1 .
- FIG. 3 is a cross-sectional view taken from FIG. 1 .
- FIG. 4 is a top view of the actuator assembly (with cover removed) for the modular EMRV of FIG. 1 .
- FIGS. 5A-5C are cross-sectional views taken from FIG. 2 showing different rotary valve body rotational positions.
- FIG. 6 is a perspective view of another example embodiment of a modular EMRV.
- FIG. 7 is a cross-sectional view taken from FIG. 6 .
- FIG. 8 is a perspective view of the mating cavity for the modular EMRV of FIG. 6 .
- FIGS. 9A-12B are cross-sectional views taken from FIG. 6 showing different rotary valve body rotational positions.
- FIG. 13A is a perspective view of the modular EMRV of FIG. 1 applied to multiple locations of an engine block of an internal combustion engine.
- FIG. 13B is a perspective view of the mating cavity for the modular EMRV of FIG. 1 .
- FIG. 14 is a perspective view of the modular EMRV of FIG. 1 applied to multiple locations of a cylinder head of an internal combustion engine.
- FIG. 15A is a perspective view of the modular EMRV of FIG. 1 applied to a multiple locations of a transmission housing.
- FIG. 15B is a cross-sectional view taken from FIG. 15A .
- FIG. 16 is side view of a first prior art EMRV.
- FIG. 17 is an isometric view of a second prior art EMRV.
- a portion of a first prior art electro-mechanical rotary valve (EMRV) 500 is shown that includes an outer housing assembly 510 having a first inlet flange 514 A, a second inlet flange 514 B, a third inlet flange 514 C, and an outlet flange 518 , all radially arranged on a cylindrical outer housing 512 .
- EMRV electro-mechanical rotary valve
- Separate first, second, and third inlet pipe components 516 A- 516 C and an outlet pipe component 520 A are attached to their respective flanges 514 A- 514 C, 518 .
- An additional outlet pipe component 520 B is attached to an end of the outer housing 510 .
- Hoses (not shown) extend from each of the inlet and outlet pipe components to various cooling system destinations to complete an engine cooling circuit.
- FIG. 17 a portion of a second prior art EMRV 600 is shown with an outer housing 610 configured with mounting features 612 A- 612 G that attach the EMRV 600 to a mounting base of a powertrain component (for example, an IC engine, transmission or differential) or any other receiving structure.
- the outer housing 610 is also configured with an external seal interface 614 to ensure that leakage does not occur between the EMRV 600 and the component or mounting surface upon which it is mounted.
- the outer housing 610 is typically injection-molded out of an expensive plastic material that can withstand extreme temperature fluctuations, and exposure to ethylene glycol or engine coolant in a vibrating and corrosive environment.
- the complexity of the outer housing 610 is significant, and therefore the design of the injection mold tooling is complex and requires significant development time and cost to incorporate many diverse exterior features while also providing interior features that require tight tolerances. Additionally, the packaging space required for the thermal management valve assembly 600 and its corresponding hoses is significant. A new design for an EMRV is needed that reduces the complexity and cost of the outer housing while lowering the packaging space.
- the modular EMRV 10 includes a valve enclosure 12 , a rotary valve body 14 , and an actuator assembly 16 .
- the valve enclosure 12 includes a central axis 18 , an inlet 20 , an outlet 22 , a hollow center 26 , and a first and a second exterior seal interface 28 A, 28 B arranged on the valve enclosure 12 .
- Optional first and second seals 29 A, 29 B can be arranged on the valve enclosure 12 to engage first and second exterior seal interfaces 28 A, 28 B. Seal interface designs other than what is shown, including but not limited to partially circumferential seal interfaces, are also possible.
- the inlet 20 is radially arranged on the valve enclosure 12 .
- Various circumferential locations of the inlet 20 are possible within the first and second seal interfaces 28 A, 28 B.
- the actuator assembly 16 is arranged at a first end 23 of the valve enclosure 12 and the outlet 22 is arranged at a second end 25 of the valve enclosure 12 .
- the actuator assembly 16 includes an actuator in the form of an electric motor 34 , a gear train 32 , and a drive shaft 30 ; other forms of actuators can also be utilized.
- the rotary valve body 14 actuated by the actuator assembly 16 , is disposed within the hollow center 26 of the valve enclosure 12 and includes a fluid pathway 36 , an actuator interface 24 , and a central axis 38 .
- Rotary motion of the electric motor 34 is transferred to the rotary valve body 14 by the gear train 32 and the drive shaft 30 .
- a first end 31 of the drive shaft 30 engages the gear train 32
- a second end 33 of the drive shaft 30 engages the actuator interface 24 of the rotary valve body 14 .
- Those skilled in the art of EMRVs are aware that other forms of actuator assemblies are possible such as those that eliminate use of the gear train 32 and/or the drive shaft 30 .
- the central axis 18 of the valve enclosure 12 is offset from the central axis 38 of the rotary valve body 14 . This non-concentricity between the rotary valve body 14 and the valve enclosure 12 provides ample radial packaging space for a rotary valve inlet seal 40 , while minimizing the outer diameter of the valve enclosure 12 .
- FIGS. 13A through 15B show different structural applications of how a single or multiple modular EMRVs 10 can be applied to various applications.
- Two modular EMRVs 10 are shown in FIG. 13A , each placed within a first and a second mating cavity 50 A, 50 B arranged on an engine block 100 of an internal combustion engine.
- the first mating cavity 50 A hereafter referred to as “the mating cavity 50 A”, serves as a fluid terminal for at least two intersecting fluid flow paths, with the modular EMRV 10 regulating the amount of fluid flow.
- the mating cavity 50 A can be formed on or within the engine block 100 by current state-of-the-art casting and machining methods.
- first and second exterior seal interfaces 28 A, 28 B of the valve enclosure 12 sealingly engage the third and fourth interior seal interfaces 58 A, 58 B of the mating cavity 50 A.
- First and second seals 29 A, 29 B may be present, as shown, between the first and second exterior seal interfaces 28 A, 28 B and the respective third and fourth interior seal interfaces 58 A, 58 B.
- the valve enclosure 12 is configured to house the optional first and second seals 29 A, 29 B, however, the mating cavity 50 A could also be configured to house the first and second seals 29 A, 29 B.
- the fourth interior seal interface 58 B is radially offset from the third interior seal interface 58 A for ease of installation; however, other seal interface designs could also be incorporated.
- First and second attachment apertures 13 A, 13 B arranged on the actuator assembly 16 are aligned with first and second reception apertures 53 A, 53 B to facilitate an appropriate rotational position and attachment of the modular EMRV 10 by fasteners (not shown); other means of attachment are also possible.
- an inlet flow passage 54 of the mating cavity 50 A is aligned with the inlet 20 of the valve enclosure 12 and the outlet flow passage 56 of the mating cavity 50 A is aligned with the outlet 22 of the valve enclosure 12 .
- the mating cavity 50 A is shown as a cylinder, any suitable form is possible to receive the valve enclosure 12 of the modular EMRV 10 .
- the arrangement shown in FIG. 13A exemplifies the versatility of the modular EMRV 10 , having a capability to be placed in multiple locations in various orientations according to packaging and functional specifications of an application.
- locations can be selected to manage localized cooling zones, as opposed to selecting a single location that necessitates a larger and more complex rotary valve assembly to manage all of the controlled coolant passages that are routed to and from that location.
- the modular EMRV 10 and mating cavity 50 A arrangement eliminates a need for hoses for external routing of coolant passages, as all coolant passages are internally routed to the mating cavity 50 A.
- the elimination of coolant hoses yields multiple benefits including weight and packaging reduction, reduced potential for leaks, and improved cooling system response times due to a reduced amount of coolant volume within the system.
- FIGS. 14 and 15A show additional arrangements of modular EMRVs 10 within a cylinder head 200 of an internal combustion engine and a transmission 300 of a vehicle, respectively.
- FIG. 15A shows a third mating cavity 50 C that extends inside of the transmission 300 , as opposed to earlier described designs in FIGS. 13A and 14 where the mating cavity protrudes outwardly from an outer wall of the engine block 100 and cylinder head 200 , respectively.
- a cross-sectional view shown in FIG. 15B shows further details of the third mating cavity 50 C that includes an inlet flow passage 54 ′ and an outlet flow passage 56 ′.
- Third and fourth interior seal interfaces 58 A′, 58 B′ are present to seal the valve enclosure 12 within the third mating cavity 50 C.
- FIGS. 5A through 5C with view to FIGS. 1 and 2 , three rotational positions of the rotary valve body 14 , a small sample of many positions that are possible, are shown that result in different fluid flows from the inlet 20 to the outlet 22 .
- FIG. 5A shows a first rotational position of the rotary valve body 14 that allows full fluid flow from the inlet 20 to the outlet 22 . In the first rotational position, the fluid pathway 36 of the rotary valve body 14 is aligned with the inlet 20 of the valve enclosure 12 .
- FIG. 5B shows a second rotational position of the rotary valve body 14 that prevents fluid flow from the inlet 20 to the outlet 22 .
- FIG. 5C shows an intermediate rotational position of the rotary valve body 14 that throttles fluid flow from the inlet 20 to the outlet 22 .
- a portion of the fluid pathway 36 of the rotary valve body is in communication with the inlet 20 which facilitates a throttling effect on fluid flow from the inlet 20 to the outlet 22 .
- the modular EMRV 60 includes a valve enclosure 62 , a rotary valve body 64 , and an actuator assembly 66 .
- the valve enclosure 62 includes a first inlet 70 A, a second inlet 70 B, an outlet 72 , a central axis 82 , and a hollow center 76 .
- the first and second inlets 70 A, 70 B are radially arranged on the valve enclosure 62 , while the outlet 72 is arranged on a second end 71 of the valve enclosure 62 .
- Sealing of the valve enclosure 62 with the mating cavity 90 is accomplished by a first exterior seal interface 78 A arranged between the actuator assembly 66 and the first inlet 70 A; a second exterior seal interface 78 B arranged between the first and second inlets 70 A, 70 B; and, a third exterior seal interface 78 C arranged between the second inlet 70 B and the second end 71 of the valve enclosure 62 .
- First, second and third seals 79 A- 79 C are optional and can be arranged on the valve enclosure 12 to engage first, second and third exterior seal interfaces 78 A- 78 C.
- the rotary valve body 64 attached to a drive shaft 84 , includes a first portion 68 A with a first fluid pathway 86 A, a second portion 68 B with a second fluid pathway 86 B, an actuator interface 67 , and a central axis 80 .
- the rotary valve body 64 could be split into two separate bodies that are attached to the drive shaft in series, with each body having a single fluid pathway, similar to the rotary valve body 14 shown in FIG. 3 .
- the central axis 82 of the valve enclosure 62 is offset from the central axis 80 of the rotary valve body 64 . This offset provides ample radial packaging space for first and second inlet seals 80 A, 80 B of the first and second inlets 70 A, 70 B, while avoiding a larger outer diameter requirement of the valve enclosure 62 .
- the mating cavity 90 serves as a fluid terminal for three intersecting fluid flow paths that extend to and from the mating cavity 90 , with the modular EMRV 60 regulating the amount of fluid flow. While the mating cavity 90 is shown as a cylinder, any suitable form is possible. Installation of the modular EMRV 60 requires insertion of the valve enclosure 62 within the mating cavity 90 until an abutment surface 65 of the actuator assembly 66 engages a mounting surface 95 . At this position, first, second, and third exterior seal interfaces 78 A- 78 C of the valve enclosure 62 sealingly engage with the fourth, fifth and sixth interior seal interfaces 98 A- 98 C of the mating cavity 90 .
- first, second, and third seals 79 A- 79 C can be arranged between the exterior seal interfaces 78 A- 78 C and respective interior seal interfaces 98 A- 98 C.
- This sealing arrangement provides for sealing isolation for each of the first and second inlets 70 A, 70 B, which prevents cross-talk between the two inlets.
- Seal interface designs other than what is shown, including but not limited to partially circumferential seal interfaces, are also possible that serve the purpose of sealing the valve enclosure 62 and providing sealing isolation for the first and second inlets 70 A, 70 B.
- First, second, third, and fourth attachment apertures 63 A- 63 D arranged on the actuator assembly 65 are aligned with first, second, third, and fourth reception apertures 93 A- 93 D to facilitate an appropriate rotational position and attachment of the modular EMRV 60 by fasteners (not shown); other means of attachment are also possible.
- the first inlet flow passage 94 A of the mating cavity 90 is aligned with the first inlet 70 A of the valve enclosure 62
- the second inlet flow passage 94 B of the mating cavity 90 is aligned with the second inlet 70 B of the valve enclosure
- the outlet flow passage 96 of the mating cavity 90 is aligned with the outlet 72 of the valve enclosure 62 .
- additional inlets could be added to the modular EMRV 60 by merely extending both the valve enclosure 62 and mating cavity 90 , and utilizing additional seal interfaces to accommodate the additional inlets.
- FIGS. 9A through 12B four rotational positions of the rotary valve body 64 , amongst many positions that are possible, are shown that result in different fluid flows from the first and second inlets 70 A, 70 B to the outlet 72 .
- FIGS. 9A / 9 B, 10 A/ 10 B, 11 A/ 11 B, 12 A/ 12 B) captures orientations of the first and second fluid pathways 86 A, 86 B of the first and second portions 68 A, 68 B of the rotary valve body 64 for a given drive shaft 84 rotational position.
- FIGS. 9A / 9 B, 10 A/ 10 B, 11 A/ 11 B, 12 A/ 12 B captures orientations of the first and second fluid pathways 86 A, 86 B of the first and second portions 68 A, 68 B of the rotary valve body 64 for a given drive shaft 84 rotational position.
- FIGS. 9A and 9B show a first rotational position that allows full, unobstructed fluid flow from both the first and second inlets 70 A, 70 B through the first and second fluid pathways 86 A, 86 B to the outlet 72 .
- FIGS. 10A and 10B show a second rotational position that prevents fluid flow from both the first and second inlets 70 A, 70 B to the outlet 72 , as no portion of the first and second fluid pathways 86 A, 86 B is aligned with the respective first and second inlets 70 A, 70 B.
- FIGS. 12A and 12B show a first intermediate rotational position that provides a throttled fluid flow from the first inlet 70 A to the outlet 72 , since a portion of the first fluid pathway 86 A is aligned with the first inlet 70 A, while preventing fluid flow from the second inlet 70 B to the outlet 72 , since no portion of the second fluid pathway 86 B is aligned with the second inlet 70 B.
- FIGS. 12A and 12B show a second intermediate rotational position that provides a throttled fluid flow from both the first and second inlets 70 A, 70 B to the outlet 72 , since only a portion of the first and second fluid pathways 86 A, 86 B is aligned with their respective first and second inlets 70 A, 70 B.
- the previously described modular EMRVs 10 , 60 provide a simplified, low-cost design that eliminates a traditional outer housing and the typical failure modes that often occur with plastic outer housings, such as cracking and leaking.
- the cumbersome packaging space associated with an EMRV is significantly reduced by eliminating all or most of the coolant hoses required for transport of engine coolant to various regions or parts of a powertrain system.
- the mating cavity 50 A can be formed on or within a powertrain component or any other receiving structure by current state-of-the-art casting and machining methods.
- the unitized design of the modular EMRVs 10 , 60 facilitates improved serviceability and adaptability to a diverse array of fluid systems.
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- Multiple-Way Valves (AREA)
- Taps Or Cocks (AREA)
Abstract
Description
- Example aspects described herein relate to electro-mechanical rotary valves for use within fluid cooling systems of vehicular powertrains.
- As fuel economy becomes paramount in the transportation industry, efforts have increased to achieve higher internal combustion (IC) engine efficiencies and to seek alternative powertrains. Coolant valves are well known and can be arranged to provide coolant flow control for temperature management of various powertrain components including internal combustion engines, transmissions and various components of hybrid electric and fuel cell vehicles.
- A portion of coolant valves are electro-mechanical in design, incorporating an actuator assembly that interfaces with a mechanical rotary valve body to provide a controlled flow of coolant to a selected powertrain component or system. An electric motor, controlled by the engine control unit, is often employed within the actuator assembly of the electro-mechanical rotary valve (EMRV) to achieve any desired angular position of the rotary valve body. A transmission or gear train can be utilized between the electric motor and rotary valve body. An injection molded plastic outer housing is typically used for an EMRV that is often mounted directly on either a cylinder head or cylinder block of the IC engine. The use of plastic provides a light-weight solution to fulfill complex outer housing design specifications that are required for mounting and sealing the EMRV to the engine, providing connections for hoses, and guiding and sealing the internal rotary valve. The outer housing must be able to withstand the rigors of a vibrating IC engine, which include large temperature fluctuations and exposure to dust, water, and salt. Additionally, all of the fasteners for either mounting or sealing of the hoses must be accessible within a crowded IC engine compartment.
- Due to these design requirements and rigorous environment, the outer housing is often one of the higher priced components of the EMRV and also contributes to many failure modes that could occur. Amongst all of the components of the EMRV, the outer housing typically requires the most time and effort to achieve a production-worthy design. A new design for an EMRV is needed that addresses these shortcomings while maintaining critical functions for current and future applications.
- A modular electro-mechanical rotary valve (EMRV) is provided that eliminates a traditional outer housing and instead utilizes a mating cavity integrated within a powertrain component or any other receiving structure. “Modular” describes the scalability, flexibility, and simplicity of the modular EMRV that can easily be installed and removed as a unit within the mating cavity, which reduces packaging space and component cost while increasing robustness and serviceability.
- The modular EMRV includes a valve enclosure, at least one rotary valve body, and an actuator assembly. The valve enclosure includes a central axis, at least one inlet, at least one outlet, a hollow center, and at least one exterior seal interface. The at least one exterior seal interface sealingly engages with at least one interior seal interface arranged within the mating cavity. At least one seal may be present between the at least one exterior seal interface and the at least one interior seal interface. The at least one rotary valve body includes at least one fluid pathway, a central axis, and an actuator interface. The actuator assembly can be located at a first end and the at least one outlet can be located at a second end of the valve enclosure. The at least one inlet can be radially arranged on the valve enclosure. The at least one rotary valve body is disposed within the hollow center of the valve enclosure. To facilitate a reduced packaging space, the central axis of the valve enclosure can be offset from a central axis of the at least one rotary valve body.
- The actuator assembly includes an actuator that rotationally actuates the at least one rotary valve body to achieve any desired angular or rotational position. Continuously variable angular positions of the at least one rotary valve body are possible to manage the fluid flows and subsequent temperatures of a fluid-cooled system. For the modular EMRV with one inlet and one rotary valve body having one fluid pathway, a first rotational position of the rotary valve body can provide full fluid flow from the inlet to the outlet; a second rotational position can prevent fluid flow from the inlet to the outlet; and, an intermediate position can throttle the flow from the inlet to the outlet. A gear train can be arranged between the actuator and rotary valve body. A drive shaft can also be arranged between the gear train and rotary valve body, with a first end of the drive shaft engaged with the gear train and a second end engaged with the rotary valve body.
- The mating cavity for the modular EMRV can be configured within but not limited to a powertrain component such as an internal combustion engine (for example, a cylinder head, engine block or front cover), transmission, or differential. The mating cavity can extend inwardly or protrude outwardly from an outer wall of the powertrain component or any other receiving structure. The mating cavity serves as a fluid terminal for intersecting fluid flow paths that interface with the valve enclosure of the modular EMRV; the flow of fluid within each of these fluid flow paths is managed by an angular or rotational position of the at least one rotary valve body disposed within the valve enclosure. Both the valve enclosure and mating cavity can be cylindrical in shape.
- The above mentioned and other features and advantages of the embodiments described herein, and the manner of attaining them, will become apparent and better understood by reference to the following descriptions of multiple example embodiments in conjunction with the accompanying drawings. A brief description of the drawings now follows.
-
FIG. 1 is a perspective view of an example embodiment of a modular electro-mechanical rotary valve (EMRV). -
FIG. 2 is another perspective view of the modular EMRV ofFIG. 1 . -
FIG. 3 is a cross-sectional view taken fromFIG. 1 . -
FIG. 4 is a top view of the actuator assembly (with cover removed) for the modular EMRV ofFIG. 1 . -
FIGS. 5A-5C are cross-sectional views taken fromFIG. 2 showing different rotary valve body rotational positions. -
FIG. 6 is a perspective view of another example embodiment of a modular EMRV. -
FIG. 7 is a cross-sectional view taken fromFIG. 6 . -
FIG. 8 is a perspective view of the mating cavity for the modular EMRV ofFIG. 6 . -
FIGS. 9A-12B are cross-sectional views taken fromFIG. 6 showing different rotary valve body rotational positions. -
FIG. 13A is a perspective view of the modular EMRV ofFIG. 1 applied to multiple locations of an engine block of an internal combustion engine. -
FIG. 13B is a perspective view of the mating cavity for the modular EMRV ofFIG. 1 . -
FIG. 14 is a perspective view of the modular EMRV ofFIG. 1 applied to multiple locations of a cylinder head of an internal combustion engine. -
FIG. 15A is a perspective view of the modular EMRV ofFIG. 1 applied to a multiple locations of a transmission housing. -
FIG. 15B is a cross-sectional view taken fromFIG. 15A . -
FIG. 16 is side view of a first prior art EMRV. -
FIG. 17 is an isometric view of a second prior art EMRV. - Identically labeled elements appearing in different figures refer to the same elements but may not be referenced in the description for all figures. The exemplification set out herein illustrates at least one embodiment, in at least one form, and such exemplification is not to be construed as limiting the scope of the claims in any manner. Certain terminology is used in the following description for convenience only and is not limiting. The words “inner,” “outer,” “inwardly,” and “outwardly” refer to directions towards and away from the parts referenced in the drawings. Axially refers to directions along a diametric central axis. Radially refers to directions that are perpendicular to the central axis. The words “left” and “right” designate directions in the drawings to which reference is made. The terminology includes the words specifically noted above, derivatives thereof, and words of similar import.
- Referring to
FIG. 16 , a portion of a first prior art electro-mechanical rotary valve (EMRV) 500 is shown that includes anouter housing assembly 510 having afirst inlet flange 514A, asecond inlet flange 514B, athird inlet flange 514C, and anoutlet flange 518, all radially arranged on a cylindricalouter housing 512. Separate first, second, and thirdinlet pipe components 516A-516C and anoutlet pipe component 520A are attached to theirrespective flanges 514A-514C,518. An additionaloutlet pipe component 520B is attached to an end of theouter housing 510. Hoses (not shown) extend from each of the inlet and outlet pipe components to various cooling system destinations to complete an engine cooling circuit. - Now referring to
FIG. 17 , a portion of a secondprior art EMRV 600 is shown with anouter housing 610 configured with mountingfeatures 612A-612G that attach theEMRV 600 to a mounting base of a powertrain component (for example, an IC engine, transmission or differential) or any other receiving structure. Theouter housing 610 is also configured with anexternal seal interface 614 to ensure that leakage does not occur between theEMRV 600 and the component or mounting surface upon which it is mounted. Theouter housing 610 is typically injection-molded out of an expensive plastic material that can withstand extreme temperature fluctuations, and exposure to ethylene glycol or engine coolant in a vibrating and corrosive environment. The complexity of theouter housing 610 is significant, and therefore the design of the injection mold tooling is complex and requires significant development time and cost to incorporate many diverse exterior features while also providing interior features that require tight tolerances. Additionally, the packaging space required for the thermalmanagement valve assembly 600 and its corresponding hoses is significant. A new design for an EMRV is needed that reduces the complexity and cost of the outer housing while lowering the packaging space. - Now referring to
FIGS. 1 through 4 , an example embodiment of amodular EMRV 10 is shown that provides a simplified design that eliminates the use of a traditional outer housing. Themodular EMRV 10 includes avalve enclosure 12, arotary valve body 14, and anactuator assembly 16. Thevalve enclosure 12 includes acentral axis 18, aninlet 20, anoutlet 22, ahollow center 26, and a first and a secondexterior seal interface valve enclosure 12. Optional first andsecond seals valve enclosure 12 to engage first and second exterior seal interfaces 28A,28B. Seal interface designs other than what is shown, including but not limited to partially circumferential seal interfaces, are also possible. Theinlet 20 is radially arranged on thevalve enclosure 12. Various circumferential locations of theinlet 20 are possible within the first andsecond seal interfaces actuator assembly 16 is arranged at afirst end 23 of thevalve enclosure 12 and theoutlet 22 is arranged at asecond end 25 of thevalve enclosure 12. Theactuator assembly 16 includes an actuator in the form of anelectric motor 34, agear train 32, and adrive shaft 30; other forms of actuators can also be utilized. Therotary valve body 14, actuated by theactuator assembly 16, is disposed within thehollow center 26 of thevalve enclosure 12 and includes afluid pathway 36, anactuator interface 24, and acentral axis 38. Rotary motion of theelectric motor 34 is transferred to therotary valve body 14 by thegear train 32 and thedrive shaft 30. Afirst end 31 of thedrive shaft 30 engages thegear train 32, and asecond end 33 of thedrive shaft 30 engages theactuator interface 24 of therotary valve body 14. Those skilled in the art of EMRVs are aware that other forms of actuator assemblies are possible such as those that eliminate use of thegear train 32 and/or thedrive shaft 30. As shown inFIG. 3 , thecentral axis 18 of thevalve enclosure 12 is offset from thecentral axis 38 of therotary valve body 14. This non-concentricity between therotary valve body 14 and thevalve enclosure 12 provides ample radial packaging space for a rotaryvalve inlet seal 40, while minimizing the outer diameter of thevalve enclosure 12. -
FIGS. 13A through 15B show different structural applications of how a single or multiplemodular EMRVs 10 can be applied to various applications. Twomodular EMRVs 10 are shown inFIG. 13A , each placed within a first and asecond mating cavity engine block 100 of an internal combustion engine. Thefirst mating cavity 50A, hereafter referred to as “themating cavity 50A”, serves as a fluid terminal for at least two intersecting fluid flow paths, with themodular EMRV 10 regulating the amount of fluid flow. Themating cavity 50A can be formed on or within theengine block 100 by current state-of-the-art casting and machining methods. Installation of themodular EMRV 10 requires insertion of thevalve enclosure 12 within themating cavity 50A until anabutment surface 15 of theactuator assembly 16 engages a mountingsurface 55. At this position, first and second exterior seal interfaces 28A,28B of thevalve enclosure 12 sealingly engage the third and fourth interior seal interfaces 58A,58B of themating cavity 50A. First andsecond seals valve enclosure 12 is configured to house the optional first andsecond seals mating cavity 50A could also be configured to house the first andsecond seals FIG. 13B , the fourthinterior seal interface 58B is radially offset from the thirdinterior seal interface 58A for ease of installation; however, other seal interface designs could also be incorporated. First andsecond attachment apertures actuator assembly 16 are aligned with first andsecond reception apertures modular EMRV 10 by fasteners (not shown); other means of attachment are also possible. In this rotational position, aninlet flow passage 54 of themating cavity 50A is aligned with theinlet 20 of thevalve enclosure 12 and theoutlet flow passage 56 of themating cavity 50A is aligned with theoutlet 22 of thevalve enclosure 12. While themating cavity 50A is shown as a cylinder, any suitable form is possible to receive thevalve enclosure 12 of themodular EMRV 10. - The arrangement shown in
FIG. 13A exemplifies the versatility of themodular EMRV 10, having a capability to be placed in multiple locations in various orientations according to packaging and functional specifications of an application. With themodular EMRV 10, locations can be selected to manage localized cooling zones, as opposed to selecting a single location that necessitates a larger and more complex rotary valve assembly to manage all of the controlled coolant passages that are routed to and from that location. Additionally, themodular EMRV 10 andmating cavity 50A arrangement eliminates a need for hoses for external routing of coolant passages, as all coolant passages are internally routed to themating cavity 50A. The elimination of coolant hoses yields multiple benefits including weight and packaging reduction, reduced potential for leaks, and improved cooling system response times due to a reduced amount of coolant volume within the system. -
FIGS. 14 and 15A show additional arrangements ofmodular EMRVs 10 within acylinder head 200 of an internal combustion engine and atransmission 300 of a vehicle, respectively.FIG. 15A shows athird mating cavity 50C that extends inside of thetransmission 300, as opposed to earlier described designs inFIGS. 13A and 14 where the mating cavity protrudes outwardly from an outer wall of theengine block 100 andcylinder head 200, respectively. A cross-sectional view shown inFIG. 15B shows further details of thethird mating cavity 50C that includes aninlet flow passage 54′ and anoutlet flow passage 56′. Third and fourthinterior seal interfaces 58A′,58B′ are present to seal thevalve enclosure 12 within thethird mating cavity 50C. - Referring to
FIGS. 5A through 5C , with view toFIGS. 1 and 2 , three rotational positions of therotary valve body 14, a small sample of many positions that are possible, are shown that result in different fluid flows from theinlet 20 to theoutlet 22.FIG. 5A shows a first rotational position of therotary valve body 14 that allows full fluid flow from theinlet 20 to theoutlet 22. In the first rotational position, thefluid pathway 36 of therotary valve body 14 is aligned with theinlet 20 of thevalve enclosure 12.FIG. 5B shows a second rotational position of therotary valve body 14 that prevents fluid flow from theinlet 20 to theoutlet 22. In the second rotational position, no portion of thefluid pathway 36 of therotary valve body 14 is in communication with theinlet 20, therefore, no fluid flow occurs from theinlet 20 to theoutlet 22.FIG. 5C shows an intermediate rotational position of therotary valve body 14 that throttles fluid flow from theinlet 20 to theoutlet 22. In the intermediate rotational position, a portion of thefluid pathway 36 of the rotary valve body is in communication with theinlet 20 which facilitates a throttling effect on fluid flow from theinlet 20 to theoutlet 22. - Now referring to
FIGS. 6 through 12B , another example embodiment of amodular EMRV 60 and amating cavity 90 are shown, along with various rotational positions to achieve different flow states. Themodular EMRV 60 includes avalve enclosure 62, arotary valve body 64, and anactuator assembly 66. Thevalve enclosure 62 includes afirst inlet 70A, asecond inlet 70B, anoutlet 72, acentral axis 82, and ahollow center 76. The first andsecond inlets valve enclosure 62, while theoutlet 72 is arranged on asecond end 71 of thevalve enclosure 62. One skilled in the art of EMRVs would understand that it would also be possible to switch the location of the outlet with one of the inlets such that the outlet is radially arranged on thevalve enclosure 62 and either the first orsecond inlet second end 71 of thevalve enclosure 62. - Sealing of the
valve enclosure 62 with themating cavity 90 is accomplished by a firstexterior seal interface 78A arranged between theactuator assembly 66 and thefirst inlet 70A; a secondexterior seal interface 78B arranged between the first andsecond inlets exterior seal interface 78C arranged between thesecond inlet 70B and thesecond end 71 of thevalve enclosure 62. First, second andthird seals 79A-79C are optional and can be arranged on thevalve enclosure 12 to engage first, second and third exterior seal interfaces 78A-78C. Therotary valve body 64, attached to adrive shaft 84, includes afirst portion 68A with a firstfluid pathway 86A, asecond portion 68B with a secondfluid pathway 86B, anactuator interface 67, and acentral axis 80. Alternatively, therotary valve body 64 could be split into two separate bodies that are attached to the drive shaft in series, with each body having a single fluid pathway, similar to therotary valve body 14 shown inFIG. 3 . As shown inFIG. 7 , thecentral axis 82 of thevalve enclosure 62 is offset from thecentral axis 80 of therotary valve body 64. This offset provides ample radial packaging space for first and second inlet seals 80A,80B of the first andsecond inlets valve enclosure 62. - The
mating cavity 90 serves as a fluid terminal for three intersecting fluid flow paths that extend to and from themating cavity 90, with themodular EMRV 60 regulating the amount of fluid flow. While themating cavity 90 is shown as a cylinder, any suitable form is possible. Installation of themodular EMRV 60 requires insertion of thevalve enclosure 62 within themating cavity 90 until anabutment surface 65 of theactuator assembly 66 engages a mounting surface 95. At this position, first, second, and third exterior seal interfaces 78A-78C of thevalve enclosure 62 sealingly engage with the fourth, fifth and sixth interior seal interfaces 98A-98C of themating cavity 90. Optional first, second, andthird seals 79A-79C can be arranged between the exterior seal interfaces 78A-78C and respective interior seal interfaces 98A-98C. This sealing arrangement provides for sealing isolation for each of the first andsecond inlets valve enclosure 62 and providing sealing isolation for the first andsecond inlets - First, second, third, and
fourth attachment apertures 63A-63D arranged on theactuator assembly 65 are aligned with first, second, third, andfourth reception apertures 93A-93D to facilitate an appropriate rotational position and attachment of themodular EMRV 60 by fasteners (not shown); other means of attachment are also possible. In this rotational position, the firstinlet flow passage 94A of themating cavity 90 is aligned with thefirst inlet 70A of thevalve enclosure 62, the secondinlet flow passage 94B of themating cavity 90 is aligned with thesecond inlet 70B of the valve enclosure, and theoutlet flow passage 96 of themating cavity 90 is aligned with theoutlet 72 of thevalve enclosure 62. One that is skilled in the art of EMRVs would understand that additional inlets could be added to themodular EMRV 60 by merely extending both thevalve enclosure 62 andmating cavity 90, and utilizing additional seal interfaces to accommodate the additional inlets. - With particular reference to
FIGS. 9A through 12B , four rotational positions of therotary valve body 64, amongst many positions that are possible, are shown that result in different fluid flows from the first andsecond inlets outlet 72. Each pair ofFIGS. 9A /9B, 10A/10B, 11A/11B, 12A/12B) captures orientations of the first and secondfluid pathways second portions rotary valve body 64 for a givendrive shaft 84 rotational position.FIGS. 9A and 9B show a first rotational position that allows full, unobstructed fluid flow from both the first andsecond inlets fluid pathways outlet 72.FIGS. 10A and 10B show a second rotational position that prevents fluid flow from both the first andsecond inlets outlet 72, as no portion of the first and secondfluid pathways second inlets FIGS. 11A and 11B show a first intermediate rotational position that provides a throttled fluid flow from thefirst inlet 70A to theoutlet 72, since a portion of the firstfluid pathway 86A is aligned with thefirst inlet 70A, while preventing fluid flow from thesecond inlet 70B to theoutlet 72, since no portion of the secondfluid pathway 86B is aligned with thesecond inlet 70B.FIGS. 12A and 12B show a second intermediate rotational position that provides a throttled fluid flow from both the first andsecond inlets outlet 72, since only a portion of the first and secondfluid pathways second inlets second inlet 70B to theoutlet 72, while preventing fluid flow from thefirst inlet 70A to theoutlet 72. - The previously described
modular EMRVs mating cavity 50A can be formed on or within a powertrain component or any other receiving structure by current state-of-the-art casting and machining methods. The unitized design of themodular EMRVs - In the foregoing description, example embodiments are described. The specification and drawings are accordingly to be regarded in an illustrative rather than in a restrictive sense. It will, however, be evident that various modifications and changes may be made thereto, without departing from the broader spirit and scope of the present invention.
- In addition, it should be understood that the figures illustrated in the attachments, which highlight the functionality and advantages of the example embodiments, are presented for example purposes only. The architecture or construction of example embodiments described herein is sufficiently flexible and configurable, such that it may be utilized (and navigated) in ways other than that shown in the accompanying figures.
- Although example embodiments have been described herein, many additional modifications and variations would be apparent to those skilled in the art. It is therefore to be understood that this invention may be practiced otherwise than as specifically described. Thus, the present example embodiments should be considered in all respects as illustrative and not restrictive.
Claims (20)
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US15/341,622 US10344883B2 (en) | 2016-11-02 | 2016-11-02 | Modular electro-mechanical rotary valve |
PCT/US2017/056939 WO2018085041A1 (en) | 2016-11-02 | 2017-10-17 | Modular electro-mechanical rotary valve |
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US15/341,622 US10344883B2 (en) | 2016-11-02 | 2016-11-02 | Modular electro-mechanical rotary valve |
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US10344883B2 US10344883B2 (en) | 2019-07-09 |
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WO2018085041A1 (en) | 2018-05-11 |
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